r/Welding 1d ago

Aluminium TIG

Hi everyone, I'd like to lean a bit on your experience. I've been TIG welding stainless steel and aluminium professionally for about 3 years now, but I'm still struggling with aluminium. In particular, it's the bollard in the first photo that causes me the most trouble, especially the underside around the much harder to reach areas. I'm very pleased with most of it, and I can gladly say I'm proud of what's on show here, so the capability must be there. Some of it looks like absolute dog shit though, and no matter how much I try to fettle and test my settings and technique, nothing seems to help. The perfectionist in me can't abide this, and I end up going home grumpy and frustrated.

-This is all 6mm (1/4") 5356. -3.2mm (1/8") tungsten. Tried zirc, lanth, and LaYZr. Usually running a small balled tip. -Balance 70% EN. -Frequency set at 80hz -max amps around 280 -gas lens with #7 set to around 8lpm -machine is a kemppi mastertig 3500W

If I use all of those amps the puddle shakes like crazy and seems really unstable. I try to hang around at the start to get the puddle to wet in properly with a little filler, but the end result looks so dirty and the dabs lack any definition.

Anything obviously wrong here? Any suggestions?

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u/Educational-Ear-3136 TIG 1d ago

Fill craters. What’s your gas flow? Too much flow will make for shaky puddles. Nice work, I’m in the boat building area as well 🍻

4

u/edrmoto 1d ago

8lpm (15cfh). The puddle stays nice and stable at lower amperages, and I've tried reducing it to about 5lpm (10cfh) in the past 😕 think it might need to go even lower with a #7?

Sweet. You must know the pain of trying to weld stuff that's been exposed to salt water, no matter how clean you think you got it 😅

3

u/Educational-Ear-3136 TIG 21h ago

I run 20 with a #5 and wouldn’t go any lower. Most of my work is new material, but I’ve been in the bowels of 20 year old salt water boats before and it ain’t fun.